Frangible concrete insert clip

ABSTRACT

A frangible clip and method for embedding a concrete insert into a concrete structure. The clip may include at least one frangible member which shears from a base member when a sufficient shearing force is applied. The clip may be formed of plastic as an integrally formed, single unit.

This application claims the benefit of U.S. provisional application U.S.Ser. No. 60/519,739, entitled “Frangible Concrete Insert Clip” and filedNov. 13, 2003, the entire contents of which are hereby expresslyincorporated by this reference.

RELATED FIELDS

The present invention relates to frangible clips and methods forembedding concrete inserts into concrete structures.

BACKGROUND

When forming concrete slabs, including floors, walls and ceilings, it isoften desirable to embed one or more inserts in the concrete. Theconcrete inserts may be various shapes and sizes useful for a variety ofpurposes.

Concrete inserts may be formed from a variety of materials, such assteel, iron, fiberglass, fiberglass reinforced plastics or othersuitable materials. The inserts may also include various finishes.Suitable concrete inserts are available from Unistrut Corporation ofWayne, Mich. and Anvil International, Inc. of Portsmouth, N.H. Theseinserts may be “continuous” inserts, “spot” inserts or any other desiredtype of insert.

Continuous inserts may include one or more channels that, when properlyinstalled, create recesses in the surface of the poured concrete. Thechannels may be used for any desired and/or suitable application,including securing other structures to the insert through the use of achannel nut or other appropriate device. The channels may also be usefulfor running wire or other similar items along the length of the channel.

Spot inserts may be used as an anchor or attachment point for a varietyof structures. Spot inserts may include threaded rods extending from theconcrete slab such that a suitable and/or desired structure can bebolted or otherwise secured to the concrete slab. Spot inserts may alsobe used as anchor points for structures such as sprinkler systems orhangers for pipes, wires or other items.

Continuous and spot inserts may be installed in any desired location,including concrete floors, ceilings and walls. Typically, concretestructures, such as walls, are formed by first erecting a concrete form.Then concrete is poured into the form and allowed to cure. After theconcrete has sufficiently cured, the form is removed, exposing theconcrete wall. The concrete forms used in this process are preferablysuited for quick erection and removal. Typically, concrete forms areconstructed from steel or wood.

Installation of concrete inserts into a wall is generally done bysecuring the insert to the concrete form such that the concrete envelopsand surrounds the insert as it is poured into the form. Removable foamfiller, or other appropriate materials, may be included in portions ofthe insert to prevent concrete from seeping into certain portions of theinsert, such as a channel. The foam filler may be removed after removalof the concrete form.

There are a number of methods for securing the concrete insert to theform. Some previous inserts are secured directly to the concrete form.These inserts include apertures allowing them to be directly secured tothe form by nails, screws or other appropriate fasteners. However,because the insert is secured directly to the form, it is difficult andtime consuming to remove the concrete form. Alternatively, metal clipsmay be used to secure the concrete insert to the form. These clipsinclude frangible portions that secure the insert to the form prior toand during concrete pouring. During removal of the form, the frangibleportions of the clip shear off, leaving the remainder of the clip, alongwith the insert, embedded in the concrete wall. These metal clips may beundesirable. First, the metal clips may be relatively expensive andcomplicated to manufacture. The frangible portions of these clips areformed from separate components, increasing the complexity and expenseassociated with producing the clips. Second, because the previous clipsare metal, the various components of the clips must be welded, formedand/or bent, also increasing the complexity and expense of production.

SUMMARY

Various embodiments of the present invention include a single pieceplastic clip adapted to secure a concrete insert to a form wall prior toand during concrete pouring and curing. The plastic clip may includefrangible portions, allowing the concrete form to be easily removed fromthe concrete wall. In some embodiments, the clip, because it is made ofplastic, may be inexpensively and easily manufactured as a one-pieceunit.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a concrete insert clip according to a first embodiment ofthe present invention in perspective view.

FIG. 2 shows a front view of the concrete insert clip shown in FIG. 1,the rear view being the same.

FIG. 3 shows a left side view of the concrete insert clip shown in FIG.1, the right side view being the same.

FIG. 4 shows a top view of the concrete insert clip shown in FIG. 1.

FIG. 5 shows a cross-section front view of the concrete insert clipshown in FIG. 1, the cross-section rear view being the same.

FIG. 6 shows the concrete insert clip of FIG. 1, a concrete insert and aconcrete form wall prior to securing the insert onto the wall.

FIG. 7 shows the insert of FIG. 6 secured to the form wall by the clip.

FIG. 8 shows a second form wall in addition to the clip, insert and wallof FIG. 7.

FIG. 9 shows the clip, insert and form walls of FIG. 8 after concretehas been poured into the form.

FIG. 10 shows the form walls of FIG. 9 partially removed from the pouredconcrete.

FIG. 11 shows the insert as well as the remaining portion of the clipembedded in the poured concrete.

DETAILED DESCRIPTION

FIG. 1 shows a concrete insert clip 10 according to a first embodimentof the present invention. In the embodiment shown in FIG. 1, clip 10 isformed from plastic in any suitable and/or desirable manner. Forinstance, clip 10 may be formed from injection molded polystyrene.Because clip 10 is formed from plastic, it can be manufactured as anintegrally formed, single unit, rather than having multiple parts.

The clip 10 shown in FIG. 1 includes a base member 12 and two frangiblemembers 14. Base member 12 may be formed with a recess 16 adapted toreceive at least a portion of a concrete insert (such as the concreteinsert 18 shown in FIGS. 6-11). Recess 16 may be formed in any suitableand/or desirable shape and size to receive and secure a wide variety ofconcrete inserts. Recess 16, however, is not limited to the size andshape illustrated in the figures.

Base member 12 may be formed with flange portions 30 on either side ofthe base member 12. Frangible members 14 may extend from flange portions30.

Preferably, clip 10 includes at least two frangible members 14, althoughonly one frangible member 14 is necessary. Clip 10 can also include morefrangible members 14 secured to base member 12 if desired. Frangiblemembers 14 may be separated from based member 12 by applying a shearingforce.

As shown in FIG. 5, the proximal ends of frangible members 14 may beapproximately co-planar with the mouth of recess 16. Because they areco-planar, in embodiments where clip 10 is used with an appropriatelysized concrete insert, mounting the concrete insert and clip 10 to aconcrete form may secure the insert flush against the form wall, suchthat there is not a gap between the insert and the wall.

Clip 10 may be formed in any desired and/or appropriate shape and size.In the embodiment shown in FIG. 1, clip 10 is approximately 2.4 inches(6.096 centimeters) in length, 3.75 inches (9.525 centimeters) in width,and 1.125 inches (2.8575 centimeters) in depth. The recess 16 shown inFIG. 1 is approximately 0.75 inches (1.905 centimeters) in length, 1.75inches (4.445 centimeters) in width, and 1.125 inches (2.8575centimeters) in depth. The recess 16 shown in FIG. 1 is of anappropriate size and shape to receive portions of a continuous strutconcrete insert, such as the concrete insert 18 shown in FIGS. 6-11. Thefrangible members 14 shown in FIG. 1 are circular tubes that areapproximately 1.5 inches (3.81 centimeters) in length and 0.3 inches(0.762 centimeters) in outer diameter.

In the embodiment shown in FIG. 5, frangible members 14 are hollowtubes. The hollow structures of frangible members 14 facilitate shearingfrom the remainder of clip 10 when sufficient shearing force is applied.The frangible members 14 may also be thinner than the other portions ofclip 10 to facilitate shearing the frangible members 14. In theembodiment shown in FIG. 5, the frangible members 14 are approximately0.1 inches (0.254 centimeters) thick while the other portions of clip 10are approximately 0.125 inches (0.3175 centimeters) thick. However, itis not necessary that frangible members 14 be thinner that otherportions of clip 10. In other embodiments, the thickness of thefrangible members 14 and other portions of clip 10 are similar. In stillother embodiments, points or lines of weakness may be included infrangible members 14 to aid in shearing.

In the embodiment shown in FIG. 5, frangible members 14 include pointedtips 20 that facilitate inserting clip 10 into concrete form walls orother desired structures. Tips 20, however, are not necessary. In otherembodiments, clip 10 does not include tips 20. The ends of frangiblemembers 14 may be formed in any desired shape and/or size. In someembodiments, the ends of frangible members 14 may include a number ofresilient arms. During insertion of the frangible members 14 into holesformed in a form wall, the resilient arms may compress. However, onceportions of resilient arms emerge on the other side of the form wall (orenter a suitable void), resilient arms may expand, locking clip 10 ontothe form wall. Other structure may also be included on or used inconjunction with frangible members 14 to secure clip 10 to the form wallsecurely. In preferred embodiments, however, these structures are notnecessary. Rather, the interaction of the frangible members 14 with theform wall is sufficient to secure clip 10, and consequently itsassociated concrete insert 18, to the concrete form.

FIGS. 6-11 show a clip 10 being used to embed a concrete insert 18 intoa concrete wall 22. As shown in FIGS. 6-11, clip 10 is used to secureconcrete insert 18 in a desired location on concrete form wall 24 priorto and during the pouring of concrete into the concrete form. In otherembodiments of the present invention, clip 10 may be used to embed aconcrete insert 18 into other concrete structures, not just walls.

FIG. 6 shows a concrete insert 18 positioned on a form 24. Form 24includes an appropriate number of holes 26 in form wall 24, sized andlocated to receive the frangible members 14 of clip 10. Holes 26 may beof a size that snugly receive frangible members 14 to securely attachclip 10 to form 24. Holes 26 may be formed in any desired manner. In apreferred embodiment, holes 26 are formed by drilling into the form 24.In other embodiments, a plurality of holes 26 are pre-formed in the form24, such that clip 10 may be installed in a number of differentpositions and/or orientations. In still other embodiments, holes 26 arenot necessary. Rather, form wall 24 may be made of a material thatallows frangible members 14 to penetrate as clip 10 is pressed againstthe form wall 24, securing clip 10 to the form wall 24.

As shown in FIG. 6, concrete insert 18 may be filled with a foam filler28 or other suitable material before or after securing insert 18 to formwall 24. Foam filler 28 may prevent concrete from seeping into undesiredportions of insert 18 during pouring and curing of the concrete. Inother embodiments, foam filler 28 is not necessary. In some embodiments,end caps may be attached to concrete insert 18, before or after securingconcrete insert 18 to form wall 24 to prevent undesired concreteseepage.

FIG. 7 shows the concrete insert 18 secured to the form wall 24 by clip10. FIG. 8 shows the inclusion of a second form wall 24, the spacebetween the form walls 24 defining a void for receiving concrete.

FIG. 9 shows poured concrete 22 surrounding and enveloping the clip 10and associated concrete insert 18. Clip 10 may secure the concreteinsert 18 in a desired location and orientation such that the pouringconcrete does not dislodge or otherwise reposition insert 18 from thedesired location and orientation.

FIG. 10 shows the form walls 24 partially removed from the sufficientlycured poured concrete 22. As shown in FIG. 10, the frangible members 14of clip 10 are sheared from the remainder of clip 10 due to theapplication of shearing force by the removal of form wall 24.

FIG. 11 shows the concrete insert 18 as well as the remaining portionsof clip 10 securely embedded in the poured concrete 22. As shown in FIG.11, the foam filler 28 has been removed from the concrete insert 18 toallow the insert 18 to be used for its intended purpose.

Changes and modifications, additions and deletions may be made to thestructures recited above and shown in the figures without departing fromthe scope or the spirit of the above description and below claims.

1. A clip for temporarily securing a concrete insert to a concrete form,comprising: (a) a base member, the base member sized and shaped toreceive at least one concrete insert; (b) at least one frangible memberextending from the base member; (c) wherein the base member and the atleast one frangible member are integrally formed; (d) wherein applying ashearing force to at least one of the base member and the at least onefrangible member separates the frangible member from the base member;and (e) wherein the clip is plastic.
 2. The clip for temporarilysecuring a concrete insert to a concrete form of claim 1, furthercomprising a second frangible member extending from the base member;wherein the base member and the second frangible member are integrallyformed; and wherein applying a shearing force to at least one of thebase member and the second frangible member separates the secondfrangible member from the base member.
 3. The clip for temporarilysecuring a concrete insert to a concrete form of claim 2, wherein thebase member comprises a recessed portion, the recessed portion sized andshaped to receive the at least one concrete insert.
 4. The clip fortemporarily securing a concrete insert to a concrete form of claim 3,wherein the base member further comprises flange portions disposed onsides of the recessed portion; wherein the frangible members extend fromthe flange portions.
 5. The clip for temporarily securing a concreteinsert to a concrete form of claim 4, wherein proximal ends of thefrangible members are approximately co-planar with a mouth of therecessed portion.
 6. The clip for temporarily securing a concrete insertto a concrete form of claim 3, wherein the recessed portion is sized andshaped to receive a portion of a continuous concrete insert.
 7. The clipfor temporarily securing a concrete insert to a concrete form of claim3, wherein the recessed portion is sized and shaped to receive a portionof a spot concrete insert.
 8. The clip for temporarily securing aconcrete insert to a concrete form of claim 1, wherein the at least onefrangible member is hollow.
 9. The clip for temporarily securing aconcrete insert to a concrete form of claim 8, wherein the at least onefrangible member comprises walls that are thinner than the base member.10. The clip for temporarily securing a concrete insert to a concreteform of claim 3, wherein the at least one frangible member includes atapered tip at a distal end.
 11. The clip for temporarily securing aconcrete insert to a concrete form of claim 1, wherein the clip ispolystyrene.
 12. The clip for temporarily securing a concrete insert toa concrete form of claim 11, wherein the clip is injection moldedpolystyrene.
 13. The clip for temporarily securing a concrete insert toa concrete form of claim 1, wherein a proximal end of the at least onefrangible member comprises a line of weakness.
 14. A method for locatinga concrete insert in a concrete structure, comprising: (a) assembling atleast a portion of a concrete form; (b) securing a concrete insert tothe concrete form using a clip, the clip comprising: (i) a base member,the base member sized and shaped to receive at least one concreteinsert; (ii) at least one frangible member extending from the basemember; (iii) wherein the base member and the at least one frangiblemember are integrally formed; (iv) wherein applying a shearing force toat least one of the base member and the at least one frangible memberseparates the frangible member from the base member; and (v) wherein theclip is plastic; (c) introducing concrete into the concrete form; (d)allowing the concrete to cure; and (e) removing at least a portion ofthe concrete form such that the at least one frangible member of theclip shears from the base member of the clip.
 15. The method forlocating a concrete insert in a concrete structure of claim 14, whereinsecuring the concrete insert to the concrete form using the clipcomprises inserting the at least one frangible member into the concreteform.
 16. The method for locating a concrete insert in a concretestructure of claim 15, wherein inserting the at least one frangiblemember into the concrete form comprises inserting the at least onefrangible member into a pre-formed hole in the concrete form.
 17. Themethod for locating a concrete insert in a concrete structure of claim15, wherein inserting the at least one frangible member into theconcrete form comprises pressing the at least one frangible member intothe concrete form.
 18. The method for locating a concrete insert in aconcrete structure of claim 14, wherein securing the concrete insert tothe concrete form using the clip comprises securing the concrete insertto the concrete form using a plurality of clips.
 19. The method forlocating a concrete insert in a concrete structure of claim 14, furthercomprising filling at least a portion of a void in the concrete insertwith a filler.
 20. The method for locating a concrete insert in aconcrete structure of claim 14, further comprising securing at least onecap on at least one end of the concrete insert.